Needleless injection device and method of injecting

ABSTRACT

A needleless injection device and method for injecting a food subject is disclosed in which one or more types of liquid food additive are individually and/or simultaneously delivered to a food subject within a sealed injection chamber or compartment. The needleless injection device and method of the present invention utilizes rapid, high pressure injection bursts to completely and uniformly inject the food subject, allowing different food subjects or different food additives to be sequentially injected in an efficient and instant manner. The needleless injection device and method for injecting minimizes contamination by totally enclosing the injection process within a sealed chamber, and by eliminating the need for the injection nozzles to contact, or be placed immediately adjacent to the food subject.

This application is a divisional of and claims priority benefit fromapplication Ser. No. 10/434,408 filed on May 8, 2003, and issued Oct.23, 2007, U.S. Pat. No. 7,284,477, the entirety of which is incorporatedherein by reference.

BACKGROUND OF THE INVENTION

This invention relates generally to devices and methods for injectingfoodstuffs, and more particularly to a needleless injecting system andmethod for needlelessly injecting a food subject with liquid.

As food tastes evolve and consumer palettes become more sophisticated,food producers and restaurateurs are finding new opportunities toexperiment with flavors, colors and innovative cuisine. Further, withcontinuous growth and competition in the food service industry, foodproducers continuously seek to distinguish their products from others byproviding consumers with foodstuffs having unique combinations ofingredients, flavors, colors, and textures.

It is desirable not only to add new flavors or spices to food, but alsocolorants for intensifying or altering the color of certain foods.Adding color to food products can increase the aesthetic appeal for thefood and enhance the natural flavors of the food. In the creation of newand unique food products, changing the color of a particular food caninstantly boost the appeal for the food to a particular consumer group.For example, a food producer may increase the desirability of a foodamong children by producing the food with vibrant or unique colors.

In addition, as scientists identify new and healthy food components, theability to increase the nutritional content of certain foods whilepreserving or enhancing the food's flavor is desirable. For example, itmay be advantageous for food producers to fortify foods lacking inmicro-nutrients such as vitamins or minerals to effectively maintain andimprove the overall nutritional quality of the food before it is served.Indeed, in an institutional setting such as a school or a hospital, itmay be highly desired to increase the nutritional content their meals.

Further, ingredients such as dietary fiber, protein, omega-3 fattyacids, triglycerides, carotenoids, terpenes, antioxidants, enzymes, fatsoluble vitamins, or other nutritionally beneficial ingredients can beadded to foods that naturally lack or lose the healthy nutritionalingredients during processing. Moreover, natural colorants derived fromfruits, plants or vegetables, such as carotene, add color to a foodstuffwhile also increasing its nutritional value.

It may also be desirable to supplement food products with otherconstituents in order to increase the taste or attractiveness of thefood to a consumer. Energy enhancing components such as ginseng, orother herbal components such as gingko biloba, may be added tofoodstuffs to increase the functional benefits of the food product.Further, preservatives such as sugar, salt, sulfites, or nitrates arecommonly added to foods such as meat, to help prevent the growth ofbacteria and maintain a food's smell, flavor and appearance.

Therefore, it would be highly desirable for food producers to be able tocustom tailor not only the flavor, color, and texture of food productsto a consumer's specific needs, but also the nutritional content andoverall appeal of the food.

In the field of meat processing, several examples of needlelessinjection devices exist. In particular, it is a common practice to cureor tenderize meat by adding salts, sugars, spices, and/or preservativesto achieve a certain effect, taste or color.

For example, U.S. Pat. Nos. 3,016,004 and 3,436,230 disclose a deviceand method for injecting preservative or other curing solution underhigh pressure into meat in a continuous processing environment. The meatis conveyed by a conveyor system to an injection station and injectionnozzles must be moved into position for injection. The injection nozzlesare brought into contact with or are positioned immediately adjacent tothe meat subject in order to eliminate damage to the meat tissue.

In addition, U.S. Pat. Nos. 5,176,071, 6,014,926, 6,165,528, 6,386,099B1also disclose large, industrial meat processing devices that convey meatsubjects into position and inject the subject using spray nozzles. Eachpatent teaches spray nozzles in direct contact or spray nozzles orientedimmediately adjacent to a meat subject.

U.S. Pat. Nos. 3,739,713 and 3,814,007 disclose a needleless injectiondevice and method for injecting in which a meat subject is secured to atable which is stationary throughout an injection. The injection nozzlesof these patents are arranged to ensure contact with the meat subjectduring an injection.

However, the aforementioned needleless injection machines and injectionmethods utilize large injection systems geared for use in large-scalemeat production/processing facilities and require significant floorspace in a plant or manufacturing facility. Many of the aforementionedpatents disclose systems that are conveyor driven to move the meatsubject into place for injection. In addition, in order to achieve auniform dispersion of fluid in the meat subject, these machines reciteinjection nozzles that are adjustable in orientation, and synchronizedwith movement of the conveyor system if possible.

Importantly, each and every one of these known devices recite methodsfor injecting meat with brines that require the injection nozzles totouch or contact the surface of the meat or food surface, increasing thechance for bacterial or microbial growth and food contamination.

U.S. Pat. No. 5,053,237 discloses a needleless injection machine forinjecting a meat subject that is placed on a stationary platform withbrine or tenderizer. The injection nozzles do not contact the injectionsubject during the injection run; however, the entire injection processincluding the liquid marinade, water bath, the injection nozzles, andall processing equipment are exposed to the wet operating environment.

Indeed, all of the aforementioned patents disclose injection systemsthat are totally exposed to the wet working environment, which adds tothe potential for contamination of the equipment and/or the meatsubject, which increases the likelihood of mechanical failure due toexposure of the process equipment to wet conditions, and which increasesthe chance for operator injury. Further, all of the aforementionedpatents provide systems or methods that are capable of delivering onlyone tenderizer/solution at a time to a meat subject, which requires thesystem to be shut down and sanitized before different or additionalsolutions can be used.

Accordingly, there is needed a device and method for uniquely flavoringor otherwise enhancing the properties of food that minimizes the riskfor food or equipment contamination, that is efficient and easy to usein a small operational environment, and that can deliver more than onetype of injection solution.

It is accordingly the primary objective of the present invention toprovide an efficient and compact needleless injection device capable ofrapidly injecting a food subject that is suitable for use in small foodproduction facilities, restaurants, or other institutional foodpreparation environments. It is a related objective of the presentinvention to provide an injection device that is easily movable from oneoperational area to another and easily positioned and installed, furthermaximizing the types of operational environments in which the device canbe used and increasing the overall utility of the device.

It is another objective of the present invention to provide a totallyenclosed, needleless injection device in which the mechanical andelectrical elements used for operation of the device are completelyenclosed within the device, increasing the safety of the device andminimizing exposure of the elements to moist or humid environments,thereby minimizing device maintenance, increasing the useful life of thedevice, and minimizing the potential for operator injury. It is arelated objective of the present invention to provide a totally enclosedinjection device that includes an injection environment that is sealedoff from the operating environment during an injection run, to minimizeexposure of the food subject to external contaminants and to minimizeexposure of moving parts to injection spray. It is yet another objectiveof the present invention to provide a needleless injection device and aninjection environment that is easy to clean and sanitize to furtherminimize the potential for food contamination.

It is yet another objective of the injection device of the presentinvention to provide injection nozzles that needlelessly inject afoodstuff without contacting the foodstuff, and without requiring thenozzles to be positioned immediately adjacent to the foodstuff, whilealso delivering a uniform dispersion of injectate within the foodsubject. It is a related object of the present invention to provideinjection nozzles that can be easily removed for cleaning, or easilyexchanged, depending on the type of food product to be injected or thepressure required to inject the subject.

It is a further objective of the present invention to provide aneedleless injection device capable of injecting more than one type offlavor, color, tenderizer, vitamin, mineral, herbal extract,anti-microbial solution, anti-bacterial solution, or other food additiveeither alone or simultaneously with other types of liquid injectateduring a single injection run. It is a related objective of the presentinvention to provide a needleless injection device capable of injectingliquid into a wide variety of food stuffs, including but not limited tomeat, cheese, fruits, or vegetables. It is a related objective of thepresent invention to provide a needleless injection device capableretaining injection fluid at its required temperature, reducing the riskof injectate spoilage.

The needleless injection device of the present invention must also be ofconstruction which is both durable and long lasting, and it should alsorequire little or no maintenance to be provided by the user throughoutits operating lifetime. In order to enhance the market appeal of theapparatus of the present invention, it should also be of inexpensiveconstruction to thereby afford it the broadest possible market. Finally,it is also an objective that all of the aforesaid advantages andobjectives be achieved without incurring any substantial relativedisadvantage.

SUMMARY OF THE INVENTION

The disadvantages and limitations of the background art discussed aboveare overcome by the present invention. Specifically, the presentinvention provides a needleless injection device and a method forinjecting a food subject with a variety of possible marinades orsolutions in an efficient, easy to use, and sanitary manner renderingthe device suitable for use in a wide number of applications such asschools, hospitals, hotels, restaurants, and other environments whereoperational space may be limited. The present invention is also highlyadvantageous over conventional systems and methods because it provides acompact, high-pressure injection system for quickly and easily flavoringor otherwise uniquely enhancing a food subject in a sealed injectionenvironment, without damaging the food subject, and without requiringnozzle contact with the food subject, thereby minimizing the potentialfor food/equipment contamination and maximizing the utility of theinvention.

The injection device and method of the present invention are used toneedlelessly inject a food subject with any type of liquid foodadditive, including but not limited to food additives such as flavors,colors, tenderizers, marinades, vitamins, minerals, herbal extracts,preservatives, fats/oils, water, anti-microbial solutions,anti-bacterial solutions, or combinations thereof. In addition, theneedleless injection device and method of the present invention can beused to inject any type of foodstuff, including but not limited tomeats, cheeses and other dairy products, fruits, vegetables, or grainproducts.

Accordingly, the injection device of the present invention generallyincludes an injectate delivery system, an injection chamber, a shuttlemechanism, and a control system configured within a sealed enclosure.External process inputs, such as electrical power, water, andoptionally, compressed air are removably connected to the device viainput ports formed within a surface of the enclosure.

The injectate delivery system of the device includes at least oneremovable container for holding liquid injectate. Preferably, severalcontainers are used for storing a variety of different types of liquidinjectate. Each container is removably mounted within the device andeach is removably connected to its own supply valve, allowing eachcontainer of injectate to be delivered to a food subject eitherindividually or simultaneously during a single injection run. Water isalso supplied to the injection delivery system, for diluting the liquidinjectate, where required, or for cleaning and rinsing the device. Theinjectate delivery system also includes a refrigeration system tomaintain the injectate containers, and water supply at the requiredtemperature to reduce the risk of injectate spoilage.

The injectate delivery system also includes a pump capable of deliveringliquid injectate a food subject at a sufficiently high pressure toneedlelessly and uniformly inject the subject with injectate withoutdamaging the food subject. The output pressure of the pump variesdepending on the size and thickness of the subject, and type of subjectto be injected. An injection head, also part of the injection deliverysystem, receives the high-pressure injectate from the pump.

The injection head contains a plurality of spray nozzles for deliveringthe high-pressure injectate to the subject, and is sealably andremovably mounted within the injection chamber with the nozzle portionof the injection head extending inside the injection chamber. Forversatility and cleaning purposes, the nozzles of the injection headare, preferably, removably secured within the injection head; however,the injection nozzles may be integrally formed within the injectionhead. The nozzles may be arranged in any pattern or configuration knownto those skilled in the art and may be reconfigured for different typesof food subjects. The injection head may also contain a filter elementfor removing unwanted particulate from the liquid injectate.

The injection chamber generally includes a sealed compartment formedwithin the device that includes a portion of the injection head, or thenozzle section of the injection head, sealably and removably mountedwithin the chamber, and extending down from the top of the chamber. Theinjection chamber includes an opening within its bottom for drainingexcess injectate from the device. The injection chamber also includescleaning nozzles which are sealably mounted within the chamber forsanitizing and rinsing the injection chamber between injection runs. Theinjection environment is sealed closed during an injection run, orduring a cleaning cycle, preventing injectate spray from contacting anyexternal process equipment, or food subjects outside the injectionenvironment.

The shuttle mechanism includes an x-y drive system located exterior toand underneath the bottom surface of the injection chamber, and ashuttle/tray component located within the injection chamber which movesthe food subject with respect to the injection head during an injectionrun. The x-y drive system includes a plate which can be moved to anyposition underneath the injection chamber. The top of the plate facesthe bottom, external surface of the injection chamber and includes aplurality of magnets affixed thereto.

The shuttle/tray component is movably located inside the injectionchamber, and contains a top surface which faces the injection nozzles,and a bottom surface which faces the bottom, internal surface of theinjection chamber. The bottom surface of the shuttle/tray componentcontains a plurality of magnets which are aligned with the magnets inthe plate. Accordingly, the x-y drive system will move the plate, whichin turn moves the shuttle/tray component to any position within theinjection chamber, without the need for moving components located withinthe injection chamber.

The control system includes a touch screen and a programmable controllerfor entering, storing, and recalling process variables and operationalinformation including but not limited to the size or types of injectionsubject; the number of injection bursts delivered to a given subject fora given injection run; the timing of the injection bursts; the durationof the injection bursts; the movement of the shuttle mechanism; thesynchronization of the injection bursts with the movement of the foodsubject; the output pressure of the pump, the outlet pressure of theinjection bursts; the composition of the injectate delivered to thesubject; or the cleaning and rinsing cycles. For example, the device maybe programmed for a specific food, a specific food thickness, or aspecific marinade blend, and later recalled when the same food ormarinade blend is again injected. The control system also controls therefrigeration system.

The present invention also teaches a method for injecting a food subjectwith liquid injectate which includes placing the food subject on ashuttle/tray component within a sealed injection environment; providinga plurality of injectate fluids to be injected; mixing said fluids inproportion to achieve the desired injectate composition; drawing thedesired injectate composition into a high-pressure pump; supplying theinjectate composition to an injection head; and delivering at least onehigh-pressure injection burst of the final injectate composition to thefood subject. The method of the present invention can also includemoving the injection subject with respect to the injection head in apreprogrammed pattern during an injection burst, depending on thedesired injection results.

In part, the present invention can also include a method for uniquelyflavoring or otherwise enhancing a food subject. Such a method comprises(1) providing a food subject to be injected; (2) determining a desiredfinal injectate composition for the food subject; (3) mixing said finalinjectate composition and supplying said composition to at least onehigh-pressure pump; and (4) delivering at least one high pressure burstof the desired injectate composition to the food subject.

It may therefore be seen that the present invention teaches a needlelessinjection device and method for injecting a food subject that utilizeshigh-pressure injection bursts of a desired injectate composition touniquely enhance a food product. The device and method of the presentinvention injects a food subject in a compact, and efficient manner,while also minimizing food or contamination, for example, by providing asealed injection environment and spray nozzles that do not contact thefood subject.

The needleless injection device and method of the present invention areof a construction which is both durable and long lasting, and which willrequire little or no maintenance to be provided by the user throughoutits operating lifetime. The needleless injection device and method ofthe present invention are also of inexpensive construction to enhanceits market appeal and to thereby afford it the broadest possible market.Finally, all of the aforesaid advantages and objectives are achievedwithout incurring any substantial relative disadvantage.

DETAILED DESCRIPTION OF THE DRAWINGS

These and other advantages of the present invention are best understoodwith reference to the drawings, in which:

FIG. 1 is an isometric view of the injection device of the presentinvention showing a front and a left side thereof, with doors shown inphantom for illustrative purposes;

FIG. 2 is left elevation view of the injection device shown in FIG. 1,with x-y drive mechanism shown exposed;

FIG. 3 an elevation view of the injection device shown in FIGS. 1 and 2,showing a partial view of the back side thereof;

FIG. 4 is a cross-sectional view of a pouch for containing injectate anda tray of the injection device shown in FIG. 3 taken along line 4-4;

FIG. 5 is a fluid schematic of the injection device shown in FIGS. 1through 4;

FIG. 6 an elevation view of the injection device shown in FIGS. 1through 5, showing a partial view front side thereof;

FIG. 7 is a detailed view of an injection head of the injection deviceshown in FIGS. 1 through 6;

FIG. 8 is a cross-sectional view of an injection head of the injectiondevice shown in FIG. 7 taken along line 8-8;;

FIG. 9 is a top plan view of an x-y drive system of the injection deviceshown in FIGS. 1 through 8;

FIG. 10 is a control schematic of the injection device shown in FIGS. 1through 8, showing automatic control of an air operation of the device;and

FIG. 11 is a control schematic of the injection device shown in FIGS. 1through 8, showing a series of preset regulators and valves.

DETAILED DESCRIPTION OF THE CERTAIN EMBODIMENTS

The preferred embodiment of the present invention involves a totallyenclosed, needleless injection device and method for injecting a foodsubject with flavors, colors, tenderizers, marinades, vitamins,minerals, herbal extracts, preservatives, fats/oils, water,anti-microbial solutions, anti-bacterial solutions, or any other foodadditive known to those skilled in the art.

Referring first to FIG. 1, a needleless injection device 30 of thepresent invention is illustrated. The device 30 includes a generallyrectangular housing defined by a frame 32 and having a front side 34, aback side 36, a left side 38, and a right side 40. The device 30 has atop 42 and a bottom 44 mounted to the frame 32 to completely enclose thetop and bottom of the device 30, respectively. The top 42 may beremovably mounted to the frame 32 in order to provide maintenance accessto the device 30. The device 30 is supported by four casters 46 foreasily moving the device 30 into place for an injection run.

The front side 34 of the device 30 contains a control panel 47 whichincludes a button or switch 48 for powering the device 30 on and off. Atouch screen 50, also part of the control panel 47, is used to enterprocess parameters, to recall a saved program from a controller 52, toinitiate a cleaning cycle, or to view operational information. The frontside 34 of the device 30 also contains an opening 54 for an injectionchamber 56, and contains doors 58 for sealing closed the opening 54.Hinges 60 secure the doors 58 to the front side 34 of the device 30 andpermit the doors 58 to open completely. A locking mechanism 62 seals thedoors 58 closed during operation of the device 30. The doors 58 may bemounted in any manner known to those skilled in the art that seals theinjection chamber 56 when the doors are closed during an injection run.

Also illustrated in FIG. 1, the front side 34 of the device 30 includesa maintenance opening 64 near the bottom 44 of the device 30. Amaintenance door 66 (shown in phantom for illustrative purposes) isprovided for closing and sealing the maintenance opening 64. Themaintenance door 66 is flush with the external surface of the frame 32.The maintenance door 66 is removably mounted to the front side 34 of thedevice 30 with machine screws 68. The maintenance door 66 may beremovably mounted in any manner known to those skilled in the art thatseals the maintenance opening 64 and that permits easy access to theinternal components of the device 30.

As illustrated in both FIGS. 1 and 2, the left side 38 of the device 30contains an access opening 70 formed near the top 42 of the left side 38of the device 30. The opening 70 is closed and sealed by an access door72 movably mounted to the left side 38 of the device 30 (shown inphantom in FIG. 1 for illustrative purposes). Hinges 74 on a bottom edgeof the access door 72 secure the access door 72 to the left side 38 ofthe device 30 and permit the access door 72 to open completely. Theaccess door 72 also contains a locking mechanism 78 near a top edge ofthe access door 72 to secure the access door 72 in a closed position.When closed, the access door 72 is flush with the external surface ofthe frame 32. The access door 72 may be movably or removably mounted inany manner known to those skilled in the art that permits easy access tothe internal components of the device 30 and closes and seals theopening 70 during an injection run.

The left side 38 of the device 30 includes a maintenance opening 82 nearthe bottom 44 of the device 30. A maintenance door 84 (shown in phantomfor illustrative purposes) is provided for closing and sealing themaintenance opening 82. The maintenance door 84 is flush with theexternal surface of the frame 32. The maintenance door 84 is removablymounted to the left side 38 of the device 30 with machine screws 86.However, the maintenance door 84 may be removably mounted in any mannerknown to those skilled in the art that closes and seals the maintenanceopening 82 during operation and that permits easy access to the internalcomponents of the device 30.

In a symmetrical fashion to the left side 38, both the right side 40 andthe back side 36 contain an access opening (not shown), such as accessopening 70 in the left side 38. Likewise, both the right side 40 and theback side 36 include an access door (not shown) similar to the accessdoor 72 in the left side 38 which is movably mounted to the right side40 and the back side 36 of the device 30, respectively. Hinges on abottom edge of each access door secures the access door to the rightside 40 or the back side 36 of the device 30, respectively, and permitthe access door to open completely in a manner similar to the left side38. The right side 40 and back side 36 access doors also contain alocking mechanism near a top edge of the access door to secure theaccess door in a closed position. When closed, each access door is flushwith the external surface of the frame 32 in a manner similar to theleft side 38.

Likewise, both the right side 40 and the back side 36 include amaintenance opening near the bottom 44 of the device 30, similar to themaintenance opening 82 in the left side 38 of the device 30. Symmetricalwith the left side 38, both the right side 40 and the back side 36include a maintenance door (not shown), similar to maintenance door 84in the left side 38, for closing and sealing each maintenance opening,respectively. Each maintenance door located on the right side 40 and theback side 36 of the device 30 is flush with the external surface of theframe 32 in a manner similar to that of the left side 38. Eachmaintenance door is removably mounted to the right side 40 or the backside 36 of the device 30, respectively, with machine screws (not shown)in a manner similar to the left side 38.

Referring back to FIG. 1 for the moment, it can be seen that the backside 36 of the device 30 includes a water input port 123 and anelectrical input port 125. In alternate embodiments, the back side 36 ofthe device 30 will also include a connection for compressed air which isexternally supplied to the device 30 where no internal compressed airsource is supplied. The back side 36 of the device also includes a drainport 124 through which excess liquid injectate, rinse water and/or spentcleaning solution can exit the device 30. The water input port 123, theelectrical input port 125, and the drain port 124 are adapted to beconnected to external hoses, piping, or connections by any means knownto those skilled in the art.

Referring to FIGS. 2 and 3, an air conditioning system 126 including acondenser 127 and a fan assembly 128 is mounted within a top portion 130of the device 30. The air conditioning system 126 ensures the liquidinjectate is at the proper temperature for injection. In particular,without refrigeration, the liquid injectate may spoil or be of atemperature that fosters microbial or bacterial growth once injectedinto a food subject.

Also referring to FIGS. 2 and 3, the top portion 130 of the device 30houses six injectate trays 132 for retaining six injectate pouches 134filled with liquid injectate. The pouches 134 are preferably one gallonin size, but can be of any volume. The pouches 134 hold any type ofliquid food additive known to those skilled in the art including but notlimited to flavors, colors, vitamins, minerals, salts, sugars,preservatives, tenderizers, marinades, herbal extracts, anti-bacterialsolutions, anti-microbial solutions, or medicines. In addition, thepouches 134 can contain water for dilution of concentrated foodadditives. The pouches 134 can be constructed of any material approvedfor food packaging including but not limited to glass, stainless steel,or food grade plastics. Optionally, the pouches 134 can be sanitizableand reusable to cut down on waste.

The trays 132 are positioned on support brackets 136 which permit thetrays 132 to slide in and out of the device 30 for easy change-out ofthe injectate pouches 134. Each tray 132 contains an opening 138 whichis in fluid communication with an outlet of the injectate pouch 134 andthrough which injectate fluid will exit the injectate pouch 134 duringoperation of the device 30, as will be described. The trays 132 areangled slightly downward towards the front side 34 of the device 30 topermit proper flow of liquid injectate out of the injectate pouches 134.Although six trays 132 and six pouches 134 are illustrated, it will beappreciated by those skilled in the art that the device 30 may containany number of trays 132 and pouches 134, depending on the particularapplication for the device. For example, a hospital may require manymore than six trays 132 and pouches 134, while a restaurant may onlyrequire four trays 132 and pouches 134.

FIG. 4 illustrates a detailed view of how the injectate pouches 134connect with the trays 132. Attached to the opening 138 in the tray 132is a quick-connect fitting 140. The pouch 134 includes a fitting 142designed to sealably mate with the quick-connect fitting 140 in the tray132. Alternatively, the liquid injectate can be provided in anycontainer known to those skilled in the art which contains a fittingdesigned to sealably mate with the quick-connect fitting 140 in the tray132.

In addition, the trays 132 may alternatively be supported within the topportion 130 of the device 30 by any means known to those skilled in theart. For example, instead of support brackets 136, the trays can besupported by means of a tongue and groove arrangement, or simply withsupport pegs.

Further, it will at once be appreciated to those skilled in the art thatliquid injectate can be supplied to the device in any manner known inthe art. For example, liquid injectate can be externally supplied to thedevice 30 using a piping mechanism or another sanitary fluid connectionthat feeds liquid injectate directly into the top portion 130 of thedevice 30. Alternatively, any container arrangement capable of retainingthe liquid injectate and housed within the top portion 130 of the device30 can be used to supply injectate for an injection run.

Turning next to FIG. 5, a fluid schematic is shown. A water line 143 isin fluid communication with the source of water via the water input port123. The water line 143 supplies water to a water reservoir 144 and isalso connected to a cleaning valve 145 which diverts water necessary forcleaning the injection chamber 56 to cleaning nozzles 174 (shown in FIG.6).

The water reservoir 144 is mounted within the top portion 130 of thedevice 30 in order to provide water for dilution of the liquidinjectate, if required, or to rinse the injection system in betweeninjection runs. A level sensor 146 provides an output to the controller52 indicating the level of water within the water reservoir 144. A waterreplenishment valve 148, located at the inlet to the water reservoir144, permits automatic replenishment of the water reservoir 144 from thewater line 143 when the level in the water reservoir 144 drops below apredetermined volumetric value as indicated by the level sensor 146.

A temperature sensor 147 provides an output to the controller 52indicating the temperature of water within the water reservoir 144. Ifthe temperature sensor 147 indicates that the water in the waterreservoir 144 is above a required operational temperature, thecontroller 52 prevents an injection run from being initiated until thetemperature drops below the required operational temperature.

A water control valve 150 is located at the outlet of the waterreservoir 144 for controlling water flow out of the water reservoir 144.In other embodiments, the water line 143 may be connected directly tothe water control valve 150 to control the flow of water in the device30, eliminating the need for a water reservoir 144. In yet anotherembodiment, a larger reservoir can be used when a water line 143 is notavailable, and the large reservoir must then be a manually replenished.

Also shown in FIG. 5, injectate transfer lines 152 are attached to eachof the openings 138 in the trays 132. Each transfer line 152 isconnected to a valve 154 for controlling the flow of liquid injectatefrom each individual injectate pouch 134. Each valve 154 can beindependently actuated, or simultaneously actuated with one or more ofthe other valves 154, or with the water control valve 150, depending onthe desired injection effect.

Lines 156 direct flow of the injectate exiting the valves 154 to amixing manifold 158. Depending of the desired injection effect, themixing manifold 158 receives injectate from one or all of the injectatepouches 134 and/or water from the water reservoir 144. The mixingmanifold 158 may be constructed of any material known to those skilledin the art that is approved for food processing or production. Themixing manifold 158 may be of any size or shape.

A high pressure pump 160, mounted within the top portion 130 of thedevice 30, draws the injectate from the mixing manifold 158 via a pumpfeed line 162. The pressure of the injectate exiting the pump 160 canrange from approximately 500 psi to approximately 3000 psi, depending onthe type of food subject to be injected. Preferably, the pressure of theinjectate at the outlet of the pump 160 ranges from approximately 1000to approximately 1800 psi. However, it is consistent with the broaderaspects of the invention that the pressure at the outlet of the pump canbe any pressure required to achieve the desired injection effect on thefood subject. Preferably, the pump 160 is an air pump, however, any pumpknown to those skilled in the art capable of delivering injectate at asufficient pressure to needlelessly inject a food subject may be used.

A pressure sensor 170 is located at the exit of the pump 160 and locatedwithin the top portion 130 of the device 30. The pressure sensor 170detects the outlet pressure of the liquid injectate and provides apressure output to the controller 52. The controller 52 is programmed torespond to the pressure output by adjusting the flow of compressed airto the pump 160 using an air pressure regulator 282 (shown in FIG. 2),thereby adjusting the output pressure of the liquid injectate to thepreprogrammed or predetermined pressure for injection. Although includedin the preferred embodiment, the pressure sensor 170, the air pressureregulator 282, and automatic control of the air operation 304 by thecontroller 52 (as shown in FIG. 10) are optional.

Referring back to FIG. 5, the injectate exits the pump 160 via a highpressure line 164 which leads to a high pressure, injection burstcontrol valve 166, also located in the top portion 130 of the device 30.The injection burst control valve 166 may be a high-pressure solenoidvalve or any high pressure valve known to those skilled in the art.Optionally, a temperature sensor 168 can be located within the line 162or line 164 to measure the temperature of the mixed injectate. Duringoperation, like temperature sensor 147 located within the waterreservoir 144, if the temperature is above the preprogrammed orpredetermined value required for a given injection run/subject, theinjection burst control valve 166 will not open.

Referring next to FIG. 6, the front side 34 of the device 30 is shown.The injection chamber 56 contains an injection head 172 which receivesthe high pressure liquid injectate exiting the injection burst controlvalve 166. While only one injection head 172 is illustrated in FIG. 6,it will be appreciated by those skilled in the art that the injectateflow exiting the injection burst control valve 166 may be divided amongtwo or more injection heads 172, depending on the particular applicationof the invention.

The injection chamber 56 also includes cleaning nozzles 174 which areremovably and sealably mounted within the injection chamber 56 forrinsing and cleaning the injection chamber 56. During a cleaning cycle,the cleaning valve 145 will be opened supplying water from the waterline 143 to the cleaning nozzles 174. The injection chamber 56 includesa drain opening 171 and a drain line 173 (shown in FIG. 5) for drainingexcess injectate from the injection chamber 56 and out of the device 30through the drain exit port 124. Optionally, the device 30 includes adrain pump housed within the device 30 which is operated periodically bythe controller 52 to avoid excess build-up in the injection chamber 56.

A shuttle 175 and a carrier tray 179 are provided for moving theinjection subject with respect to the injection head 172 during aninjection run. The shuttle 175 is a substantially rectangular platecontaining apertures (not shown) for draining excess liquid injectate.The shuttle 175 includes a plurality of magnets 177 affixed thereto formoving the shuttle 175 within the injection chamber 56 without locatingmechanical or electrical components within the injection chamber, aswill be described.

The carrier tray 179 is removably coupled to the shuttle and rides onthe shuttle 175 during an injection run. The tray 179 can be coupled tothe shuttle 175 in several different positions in order to vary theheight of the injection subject with respect to the injection head 172.The shuttle 175 and the tray 179 are located within the injectionchamber 56 and are removable therefrom for cleaning.

The shuttle 175 and the tray 179 can be of any size or shape, dependingon the desired injection effect or on the type of food subject theshuttle 175 and the tray 179 are designed to carry. For example, inorder to bring a food subject closer to the injection head 172, theshuttle 175, or the tray 179 can be greater in height than indicated inFIG. 6 to provide a platform for the food subject. Accordingly, it iscontemplated that multiple shuttles 175 and multiple carrier trays 179may be provided with the device 30, for different food-subjectapplications of the invention.

Referring next to FIGS. 7 and 8, in addition to FIG. 6, a detailed viewof the injection head 172 is shown. The injection head 172 issubstantially cylindrical in shape and includes a top section 176 and abottom section 178 which is removably connected to the top section 176.The injection head 172 and all related components are preferablyconstructed of stainless steel; however, the injection head 172 may beconstructed of any material known to those skilled in the art capable ofwithstanding the high system pressures required to needlelessly injectsubjects.

The top section 176 of the injection head 172 has a cylindrical, outersurface indicated generally at 180, a bottom surface indicated generally182, and a top surface indicated generally at 184 (shown in FIG. 5). Aportion 186 of the outer surface 180 of the top section 176 containsthreads 188 for removably threading the top section 176 on to the bottomsection 178 of the injection head 172.

Referring to FIG. 5, in addition to FIG. 7, the inside portion of thetop surface 184 of the top section 176 is concave, or dome-shape, andincludes a fluid-in port 190 which receives the high pressure injectateexiting the injection burst control valve 166. The top surface 184 alsoincludes an air release port 192, located at the highest point along thetop surface 184 of the top section 176, for releasing any trapped airwithin the injection head 172.

A fast-acting, solenoid escape valve 194 is connected to the air releaseport 192 for releasing any air trapped in the system. The outlet of theescape valve 194 is connected to a drain line 195 for directing anyentrained injectate out of the device 30 through the drain port 124. Thedrain line 195, carrying excess injectate flowing out the air releaseport 192, can be in fluid communication with the drain line 173 beforeexiting the device 30 through the drain port 124.

Turning back to FIGS. 7 and 8, the bottom section 178 of the injectionhead 172 contains a cylindrical, outer surface indicated generally at196, a bottom surface indicated generally 198, and a top surfaceindicated generally at 200. The bottom surface 198 of the bottom section178 contains a plurality of apertures 206 through which liquid injectatecan exit the injection head 172. The bottom section 178 contains acavity 202 including threads 204 located near the top surface 200 of thebottom section 178 for removably coupling the bottom section 178 to thetop section 176. The bottom section 178 may alternatively be removablyconnected to the top section 176 in any manner known to those skilled inthe art.

A nozzle disc 208, having a top side 210 and a bottom side 212, isremovably located within the cavity 202 of the bottom section 178 of theinjection head 172. The nozzle disc 208 is keyed so that it fits withinthe cavity 202 in only one direction, making assembly of the injectionhead 172 easier. The nozzle disc 208 contains a plurality of openings214 for accommodating a plurality of injection nozzles 216. Each opening214 in the nozzle disc 208 contains a lip 218 located near the bottomsurface 212 in order to removably retain the injection nozzles 216within the openings 214 of the nozzle disc 208. When installed for aninjection run, the openings 214 in the nozzle disc 208 are aligned withthe apertures 206 located within the bottom surface 198 of the bottomsection 178 of the injection head 172. The nozzle disc 208 is removablefrom the injection head 172, and the nozzles 216 are removable from thenozzle disc 208 for cleaning of the entire injection head assembly.

Each injection nozzle 216 has an orifice 220 for delivery of the liquidinjectate to the injection subject. The orifice 220 in each in injectionnozzle is preferably less than 0.025 inches and more preferablyapproximately 0.006 inches. Consistent with the teachings of the presentinvention, it will be apparent to one skilled in the art that theorifice 220 in the injection nozzles 196 may be greater than 0.025inches or less than 0.006 inches depending on the type or thickness ofthe subject to be injected. Accordingly, the orifice 220 of each nozzle216 may be of any size that permits delivery of injection bursts at apressure sufficient to uniformly and needlelessly inject the foodsubject with injectate without damaging or deforming the food subject.

The nozzles 216 are constructed of sapphire, or any material known tothose skilled in the art capable of withstanding the high-pressure fluidbursts required for the needleless injection of subjects. Further,nozzles 216 can be easily changed depending on the subject to beinjected and the desired injection objectives. While the nozzles 216 areshown removably placed within the nozzle disc 208 of the injection head172, the nozzles 216 may instead be integral with the nozzle disc 208,or integral within the bottom surface 198 of the bottom section 178 ofthe injection head 172. Further, the nozzles 216 may be removablyattached to the injection head 172 in any manner known to those skilledin the art.

In addition, while sixteen nozzles 216 are illustrated, more or lessnozzles may be used depending on the desired injection effect and typeof food subject. For example, for larger or thicker injection subjectstwenty-four nozzles 216 may be used in conjunction with a nozzle dischaving a corresponding number of openings. Also, while a rectangularinjection pattern is illustrated, it is contemplated that the injectionnozzles 216 can be arranged in a circular pattern or in any otherconfiguration, depending on the desired injection effect to be achieved.

To assemble the injection head 172 in preparation for an injection run,the nozzles 216 are placed within the openings 214 in the nozzle disc208 and the nozzle disc 208 is placed bottom side 212 down into thebottom section 178 of the injection head 172. An O-ring 222 and a washer224 are placed into the bottom section 178 of the injection head 172after the nozzle disc 208 and nozzles 216 are in position. When the topsection 176 is coupled to the bottom section 178, the O-ring 222 and thewasher 224 prevent the injectate from flowing around the nozzle disc208. The washer 224 is provided with a small groove 226.

A disk filter 228 is positioned within the bottom section 178 of theinjection head 172 over the O-ring 222 and the washer 224. The filter228 is generally a disk-shaped element having a front side 230, a backside 232, a flat peripheral edge 234, and a plurality of apertures (notshown) formed within the filter 228. The peripheral edge 234 engages thesmall groove 226 in the washer 224 when the filter 234 is properlypositioned within the bottom section 178 of the injection head 172.During operation, injectate passes through the apertures of the filter228 to remove particulate in the liquid injectate before entering thenozzles 216.

After the filter 228 is installed in the bottom section 178 of theinjection head 172, a second O-ring 238 is positioned in bottom section178 of the injection head 172 over the filter 228 so that the O-ring 238engages the peripheral edge 234 on the top side 234 of the filter 228.After the O-ring 238 is installed, the bottom section 178 is threadedonto and hand tightened on the top section 176 of the injection head172. Accordingly, during an injection run, the incoming injectate doesnot contact any of the threading, grooves, or pitting that may bepresent in either the top section 176 or the bottom section 178.

Further, because residual injectate does not become trapped within thethreaded connection or pass through it, the risk for fluid contaminationis decreased. In addition, the configuration of the injection head 172may increase the useful life of the injection head 172, as thread orgrooves exposed to acidic conditions (cleaning fluid or injectate) tendto pit easily or rust.

The O-rings 222, 238 can be constructed of a material such as those soldunder the trademark TEFLON by DuPont, Inc. or its licensees, EPDM(Ethylene Propylene Diene Monomer), silicone, rubber, or any othermaterial known to those skilled in the art for sealing the internalcomponents of the injection head 172 in place as well as sealing thebottom section 178 on to the top section 176 of the injection head 172.It will at once be appreciated by those skilled in the art that the topsection 176 and the bottom section 178 of the injection head 172 can beremovably sealed together by any means known to those skilled in theart.

Referring for the moment back to FIGS. 5 and 6, the top section 176 ofthe injection head 172 is mounted to the device 30 such that the topsurface 184 of the top section 176 extends into or faces the top portion130 of the device 30. The bottom surface 182 of the top section 176extends into the injection chamber 56. Accordingly, the bottom section178 of the injection head 172 is removably attached to the top section176 from within the injection chamber 56.

The top section 176 is completely sealed around the external perimeterof its outer surface 180 at the intersection of the top section 176 andthe injection chamber 56 to prevent liquid injectate from spraying orotherwise entering the top portion 130 of the device 30. The top section176 is sealed in place by a sealing mechanism 240 which can includemachine screws, and/or an O-ring or any mechanical sealing device knownin the art which can seal the injection chamber 56 around the perimeterof the top section 176. In this way, the injection head 172 isstationary during an injection run. However, in this arrangement, thetop section 176 can be removed from the device 30 for maintenancepurposes, or to change the size or type of injection head.

The top section 176 of the injection head 172 can be removably sealedinto place in any manner known to those skilled in the art. In alternateembodiments, the injection head 172 may be removably sealed in such amanner that permits the injection head to be adjustable in height withinthe injection chamber 56. In yet other embodiments, the top section 176of the injection head 172 can be permanently welded or otherwise adheredto the device 30.

It will appreciated by those skilled in the art that the injection head172 may be of any shape or size, provided that adequate fluid pressurecan be achieved at the outlet of the nozzles 216 to provide for theneedleless injection of the food subject. For example, the injectionhead 140, rather than being cylindrical in shape, can be round orgenerally tubular in shape having apertures and bearing nozzles withinany surface of the injection head.

Referring next to FIG. 9, in addition to FIG. 6, an x-y drive system 246is illustrated. The x-y drive system 246 is located underneath theinjection chamber 56 and can be accessed through any of the maintenanceopenings in any of the sides of the machine 34, 36, 38, 40. The x-ydrive system 246 moves the shuttle 175 within the injection chamber 56from underneath the injection chamber 56, eliminating the need formoving parts within the injection chamber 56. The x-y drive system 246contains a table 248, and two parallel tracks 250 that are mounted tothe table 248 on the left and right sides 38, 40 of the device 30respectively, and which extend from the front side 34 to the back side36 of the device 30. A first drive system 252, including a motor 254 anda drive belt 256, is also mounted to the table 248.

An x-y platform 258 is movably mounted to the parallel tracks 250,extending from the left side 38 to the right side 40 of the device 30.Two parallel tracks 260 which extend from the left side 38 to the rightside 40 of the device 30 are mounted to the x-y platform 258. A seconddrive system 262, including a motor 264 and a drive belt 266, is alsomounted to the x-y platform 258. An x-y drive plate 268 (best shown inFIG. 6) is movably mounted to the parallel tracks 260.

Support columns 270 are generally cylindrical in shape, having one endwith a smaller circumference than the other, such that the transitionbetween the large circumferential portion and the smallercircumferential portion forms a shoulder 330. The large circumferentialportions of each support column 270 are mounted to the x-y drive plate268. A plate 272 having apertures 332 on one of two opposing sides iscarried by the support columns 270 such each aperture 332 within theplate 272 slidably receives the smaller circumferential portion of eachsupport column 270, respectively, and such that the plate may rest onthe shoulders 330 of the support columns 270. A plurality of magnets 274are affixed to the plate 272, and are arranged on the plate 272 insubstantially the same configuration as the magnets 177 on the shuttle175 located within the injection chamber 56.

By virtue of the magnetic attraction between the magnets 274 on theplate 272 and the magnets 177 on the shuttle 175, the plate 272vertically slides along the support columns 270 between the shoulders330 and the end of the support columns 270 in a manner that allows theplate 272 to account for the slope in the bottom of the injectionchamber 56, irregularities in the bottom of the injection chamber 56,and/or allows the plate 272 to account for misalignments between the x-ydrive system 246 and the bottom of the injection chamber 56 when the x-ydrive system 246 is operating.

During an injection run, the first drive system 252 moves the x-yplatform 254, and in turn moves the plate 272 with magnets 274 affixedthereto, to any position located from the front side 34 of the device 30to the back side 36 of the device 30 in accordance with a particularpreprogrammed injection pattern, or in accordance with a predeterminedinjection effect to be achieved. Simultaneously, the second drive system262 moves the x-y drive plate 268, which in turn moves the plate 272with magnets 274 affixed thereto, to any position located from the leftside 38 of the device 30 to the right side 40 of the device 30 inaccordance with a particular preprogrammed injection pattern, or inaccordance with a predetermined injection effect to be achieved.Accordingly, the plate 272 can be moved in any direction, and to any x-yposition within the device 30.

Thus, during an injection run, the magnets 177 on the shuttle 175 withinthe injection chamber 56 are aligned to match up with the magnets 274that are affixed to the plate 272. The plate 272, by means of magneticattraction, will then drive the shuttle 175 to any location within theinjection chamber.

It will be appreciated that any drive or positioning mechanism known tothose skilled in the art can be used to move the injection subjectwithin the injection chamber 56. This includes not only any linearpositioning system such as a servo motor-lead screw type drive, butalso, any rotary or nonlinear automated positioning system known tothose skilled in the art.

Turning back to FIGS. 1 and 2, an equipment compartment 276 locatedwithin a bottom portion of the device 30 is illustrated. The equipmentcompartment 276 is included within the device 30 for locating anyrequired electrical and mechanical equipment within the device 30. Theequipment compartment 276 extends from the front side 34 to the backside 36, and from the right side 40 to left side 38 along the bottom 44of the device 30.

An air compressor 278, a compressed air tank 280, and the air pressureregulator 282 are mounted within the equipment compartment 276 forsupplying compressed air to the pump 160 and to any compressed airdriven equipment required for the device 30. In alternate embodiments,the device 30 may not be supplied with an internal air compressor 278.In these embodiments, an external compressed air source is used tosupply the requisite compressed air to the device 30, and is connectedto the device 30 via an input port formed in the back side 36 of thedevice 30, which in turn is connected directly to the compressed airtank 280.

A compressor 286 for use with the air conditioning system 126, and thecontroller 52 are also located within the equipment compartment 276. Inaddition, any other equipment necessary for operation of the device 30may be included within the equipment compartment 276. Further, anyequipment housed within the top portion 130 of the device 30, such asthe air pump 160, the water reservoir 144, valves 146, 148, 154, 166, or194, and any associated piping, may be optionally located within theequipment compartment 276, depending on the dimensions and spacerequirements of the device 30. Likewise, any equipment housed within theequipment compartment 276 can alternatively be located within the topportion 130 of the device, 30 or any other location within the device30, depending on the dimensions and space requirements of the device 30.

Finally, while the device 30, as shown, is generally a rectangularhousing, it will be at once appreciated by those skilled in the art thatthe device 30 may be of any size, shape, or dimensions required toaccommodate the device 30 in an institutional setting. Accordingly,consistent with the broader aspects of the invention, the device 30 maybe custom-sized to fit into an existing space at any intended location.

It can be seen that the present invention includes a method of usingsubstantially uniform, high-pressure injection bursts to instantly andneedlelessly inject a food subject with injectate fluid. In this way,damage to the external surfaces of the subject is minimized. The presentinvention also includes a method of instantly delivering injection fluidto a subject using substantially uniform, high-pressure injection burstsof a sufficient pressure to needlelessly add flavors, colors,preservatives, binders, herbal extracts, vitamins, minerals,anti-microbial solutions and/or tenderizers to an injection subjectwithout significant damage to the external surfaces of the injectionsubject.

Accordingly, referring to FIGS. 1 through 11, operation of theneedleless injection device 30 of the present invention will now bedescribed. First, an operator will attach an external water supply lineto the water input port 123, an electrical power line to the electricalinput port, and a compressed air line (if there is no internal aircompressor 278) to the back side 36 of the device 30. A drain line isconnected to the drain port 124.

The injectate pouches (containing the liquid injectate) are loaded intothe device 30, and connected to the quick connect fittings 140 in eachof the trays 132. Preferably, the injectate pouches 134 are refrigeratedto the proper temperature before being loaded into the device 30. Inaddition, whenever the device 30 is plugged in, the air conditioningsystem 126 will be running, maintaining the top portion 130 of thedevice 30, and any injectate pouches 134 stored therein, at the propertemperature. In this way, even when not performing an injection run, thedevice 30 can remain plugged in to store the liquid injectate at theproper temperature between runs.

To initiate an injection run, the operator turns on the device 30 usingthe button 48 located on the control panel 47. The operator then followsthe prompts indicated on the touch screen 50 and enters injection runprocess parameters for controlling the device. Such parameters includebut are not limited to the food type, the thickness of the food, thedesired injectate pouch(es) (or tray number(s) in which it is located),the batch size, the injection pressure, duration of the injectionbursts, spacing between injection bursts, timing of the injections, theoutput pressure of the air pump 160, the movement of the shuttle 175, orany other information necessary for a given injection run. Theseparameters may be adjusted during the production run in accordance withthe required injection effect to be achieved by the machine.

Alternately, the operator can use the touch screen 50 to retrieve fromthe controller 52 a stored set of process variables for a giveninjection subject or for a given injection effect. The preprogrammedprocess variables can include control of the injection pressure,duration of the injection bursts, spacing between injection bursts,timing of the injections, the output pressure of the air pump 160, themovement of the shuttle 175, or any other information necessary toinject a given type of subject.

As part of a fluid operation 300, the controller 52 may be programmed toautomatically replenish the water reservoir 144 during an injection runvia the water replenishment valve 148 when the water level drops below apredetermined level as indicated by level sensor 146 (as illustrated inFIG. 10). Accordingly, no operator intervention will be required tomaintain a high level of water within the water reservoir 144.Alternatively, if the water reservoir 144 becomes low, the touch screen50 may indicate to the operator that the level is low and will permitthe operator to refresh the injectate fluid automatically using thecontroller 52. In addition, the operator can pause the operation of thedevice 30 and manually refill the water reservoir 144.

The operator places the injection shuttle 175 within the injectionchamber 56 so that the magnets 177 affixed thereto are aligned with themagnets 274 affixed to the plate 272 on the x-y drive system 246. Thecarrier tray 179 is then placed on to the shuttle 175 in the positionrequired for achieving the desired injection effect on the subject, andthe injection subject is then placed on the carrier tray 179.

In order to begin an injection run, the doors 58 on the injectionchamber 56 are closed. As part of a safety door operation 302 of thedevice 30, the doors 58 on the injection chamber 56 contain a sensor 284which is interlocked with the controller 52. The controller will notpermit an injection run to be initiated if the doors 58 are open.

During operation, liquid injectate from one or more of the selectedinjectate pouches 134 will flow through the openings 138 in each of theselected trays 132 to the injectate control valves 154, respectively.The injectate control valves 154 then open to permit injectate to flowto the mixing manifold 158 via line 156. If desired, water from thewater reservoir 144 will also flow to the mixing manifold to dilute theinjectate.

Also part of the fluid operation 300 of the device 30, the temperaturesensor 147 relays the water temperature to the controller 52. If thewater temperature is higher than a predetermined operationaltemperature, a temperature warning light will appear on the touch screen50 and the controller 52 will prevent the injection burst control valve166 from opening. If this occurs, the operator must wait until the airconditioning system 126 cools the water to the proper temperature, andthe warning light disappears. In addition, and to speed cooling, crushedice can be added to the water reservoir 144. If the warning lightappears during an injection run, the running program will be allowed tofinish; however no further cycles can be initiated until the watersupply is cooled to the proper temperature, and the warning lightdisappears.

Control and timing of the injectate control valves 154 and the watercontrol valve 146 will influence the final composition of the liquid tobe injected into the food stuff. Therefore, as part of the fluidoperation 300 of the device 30, the control and timing of the injectatecontrol valves 154 and the water control valve 150 are controlled by thecontroller 52 in order to achieve a predetermined injectate composition.

It will be appreciated by those skilled in the art that a given foodsubject may require more than one injection burst for a given run.Therefore, the composition of the “mixed injectate” can be changed bychanging the timing and control of the injectate control valves 154 frominjection burst to injection burst, or during and injection burst,depending on the desired injection effect to be achieved.

The mixed injectate exits the mixing manifold 158 via the pump feed line162 and flows to the low-pressure side of the injection pump 160, alsowithin the top portion 130 of the device 30. The air pump 160 pumps theinjectate to the injection burst control valve 166 via high pressureline 164.

As part of an air operation 304 of the device 30, the output pressure ofthe fluid is relayed from the pressure sensor 170 to the controller 52,as illustrated in FIG. 10. If the required injection pressure has notbeen attained, the controller 52 automatically responds by adjusting theair pressure regulator 282 to change the air pressure flow to the pump160 until the output pressure of the pump has reached the required orpreprogrammed injection pressure. In alternate embodiments, the operatormay be permitted to manually adjust the air flow to the pump 160 via thetouch screen 50. Although automatic control of the air operation 304 isincluded in the preferred embodiment, automatic control is optional.

An alternative to automatic control of the air operation is illustratedin FIG. 11. A series of preset regulators 167 a, 167 b, 167 c and valves169 a, 169 b, 169 c are used to regulate air flow from a compressed airtank 280 to the pump 160, thereby changing the output pressure of thepump 160 between three predetermined injection pressures. When the typeor thickness of the food subject is entered by the operator using thetouch screen 50, the controller 52 responsively activates thecorresponding valve 169 a, 169 b, or 169 c which directs flow ofcompressed air to the associated regulator 167 a, 167 b, 167 c, allowinga predetermined flow rate of air to feed the pump 160. This causes thepump 160 to deliver injectate at the predetermined output pressurecorresponding to the particular activated valve. While three presetpressure regulators 167 a, 167 b, 167 c and valves 169 a, 169 b, 169 care illustrated in FIG. 11, any number of preset regulators and valvescorresponding to any number of predetermined output pressures of thepump 160 may be used.

Optionally, the temperature sensor 168 relays the injectate temperatureto the controller 52. If the temperature is too high, a temperaturewarning light will appear on the touch screen 50 and the controller 52will prevent the injection burst control valve 166 from opening. If thisoccurs, the operator must wait until the air conditioning system 126cools the injectate to the proper temperature, and the warning lightdisappears. If the warning light appears during a run, the runningprogram will be allowed to finish; however no further cycles can bestarted until the injectate is cooled to the proper temperature, and thewarning light disappears.

When the injectate is at proper temperature, the injection control valve166 opens to direct injectate to flow to the injection head 172. Theinjection bursts then occur in conjunction with the preprogrammed orpreviously entered process parameters and are completely synchronizedwith the movement of the x-y drive system 246 as part of a shuttleoperation 306.

Accordingly, the injection subject (located on the carrier tray 179) ismoved with respect to the injection head 172 and is injected accordingto the desired results. The shuttle 175 and carrier tray 179, and inturn the injection subject, can be moved during an injection burst, orcan be moved in between injection bursts depending on the desiredinjection effect. Thus, when the subject is in place, the injectionburst control valve 166 opens allowing fluid to be delivered to thesubject through the nozzles 216 on the injection head 172. After aninjection burst is complete, the injection burst control valve 166 isclosed. An injection subject can receive as many injection bursts asnecessary to achieve the desired results.

Periodically during an injection run, the fast-acting solenoid valve 194connected to the air release port 192 is opened to relieve any airbuild-up within the injection head 172. If the valve 194 is notpreprogrammed to open at a given interval, the operator can use thetouch screen 50 to cause the valve 194 to open periodically. Anyinjectate that exits the air release port 192 will flow via the drainline 195 out of the device 30 through the drain port 124.

Excess injectate flows in the injection chamber 56 flows through thedrain opening 171 and out of the device 30 through the drain port 124.If a drain pump is provided, the controller 52 will automatically turnthe pump on and off to avoid excess injectate build-up in the injectionchamber 56.

After all injection bursts for a given subject have been delivered, theoperator may then open the doors 58 on the injection chamber 56 andremove the injected food subject. Complete and uniform injection of afood subject with a liquid injectate in the manner described herein,occurs in a manner of seconds, depending on the type injection subject.The instantaneous nature of an injection run of the present inventionrenders the device useful in restaurants or cafes where the timing offood delivery is critical.

As part of a cleaning operation 308, in between each injection run, theinjection head 172, injection nozzles 216, and associated valves andlines may be rinsed with water from the water reservoir 144. Theinjection chamber 56 is rinsed with water diverted from the water line153 using the cleaning nozzles 174. However, after a specified number ofhours of operation set by a timer 290, the touch screen 50 willautomatically prompt the operator to run a cleaning cycle. Preferably,the specified time period is four hours.

In addition, in between injection runs, and prior to shutting down themachine, the touch screen will include a control, e.g. a switch or abutton, for initiating a cleaning cycle. The operator will then followthe prompts indicated to clean and sanitize the device. If a cleaningcycle is not run before the device 30 is shut down, a cleaning cyclecontrol will be indicated on the touch screen 50 when the device 30 isrestarted.

During a cleaning cycle, the operator is prompted to use the touchscreen 50 to open the cleaning valve 145 in order to divert the watersupply entering the water reservoir 144 to the cleaning nozzles 174.Optionally, cleaning solution is supplied to the device 30 through thewater input port 123 along with the external water supply. However, thecleaning solution can be supplied to the water input port 123 in anymanner known to those skilled in the art. The doors 58 of the injectionchamber 56 are then closed and sealed, and the cleaning cycle is startedby the operator via the touch screen 50. When the cleaning cycle iscompleted, the doors 58 of the injection chamber 56 are opened, andadditional injection runs can occur.

In addition, the cleaning operation can include removing the injectionhead 172, and disassembling it for manual cleaning of the filter,O-rings, the washer, the nozzle disc, and the nozzles.

It may therefore be seen that the present invention teaches a needlelessinjection device and method for needlelessly injecting a food subject inwhich one or more types of liquid food additive are individually and/orsimultaneously delivered to a food subject within a sealed injectionchamber or compartment, with complete and uniform injection of the foodsubject occurring in a matter of seconds. The needleless injectiondevice and method of the present invention minimizes contamination bytotally enclosing the injection process within a sealed chamber, and byeliminating the need for the injection nozzles to contact, or be placedimmediately adjacent to the food subject.

It may further be seen that the present invention teaches a needlelessinjection device and method for injecting a food subject that isefficient and compact for use in operational areas where conveyorsystems, or large production equipment are unnecessary, or tooexpensive. Further, the present invention provides a method for uniquelyflavoring or otherwise enhancing a food subject in a stand-alone devicethat can be rinsed or cleaned between each food subject. The presentinvention permits a new/different food subject, or a new/differentflavor combination to be injected for sequential injection runs, withoutrequiring “shut-down” of an entire production line, or an entirerestaurant operation.

Although an exemplary embodiment of the present invention has been shownand described with reference to particular embodiments and applicationsthereof, it will be apparent to those having ordinary skill in the artthat a number of changes, modifications, or alterations to the inventionas described herein may be made, none of which depart from the spirit orscope of the present invention. All such changes, modifications, andalterations should therefore be seen as being within the scope of thepresent invention.

1. A method for injecting a subject comprising: providing a plurality ofsources for retaining liquid; selectively mixing the liquid from atleast two of said sources to achieve a desired injectate composition;supplying said injectate composition at a high pressure to at least onestationary injection head; delivering at least one constant, highpressure burst of said injectate composition to the subject.
 2. A methodfor injecting a subject as defined in claim 1, wherein said providingstep includes cooling each of the sources of liquid to a predeterminedtemperature.
 3. A method for injecting a subject as defined in claim 1,wherein said mixing step includes adding a controlled volume of liquidfrom one or more of said sources of liquid to a mixing manifold untilthe desired injectate composition is achieved.
 4. A method for injectinga subject as defined in claim 1, wherein said supplying step includesdrawing the desired injectate composition into at least one highpressure pump and delivering the injectate composition at a highpressure to the injection head.
 5. A method for injecting a subject asdefined in claim 1, wherein said supplying step includes filtering theinjectate composition as it enters the injection head.
 6. A method forinjecting a subject as defined in claim 1, wherein said delivering stepincludes delivering at least one constant, high pressure injection burstto a subject in a sealed injection environment.
 7. A method forinjecting a subject as defined in claim 1, further comprising at leastone of: monitoring the output fluid temperature of at least one of theliquid sources with a temperature sensor; displaying an output of thetemperature sensor on a screen to indicate that the output fluidtemperature is above a predetermined operational temperature; anddelaying delivery of injection bursts to the subject until the outputfluid temperature is equal to or below the predetermined operationaltemperature.
 8. A method for injecting a subject as defined in claim 1,further comprising at least one of: monitoring the pressure of theinjectate composition at an inlet of the injection head; and adjustingthe pressure of the injectate composition entering the injection head toachieve a predetermined injection burst pressure.
 9. A method forinjecting a subject as defined in claim 1, further comprising at leastone of: providing relative movement between the injection subject andsaid injection head in between injection bursts to achieve the requiredinjection position for a given injection burst; and synchronizing themovement of the injection subject with the injection burst parameters toachieve a predetermined injection effect on the injection subject.
 10. Amethod for injecting a subject as defined in claim 1, further comprisingat least one of: providing relative movement between the injectionsubject and said injection head during an injection burst to achieve therequired injection effect for a given injection run; and synchronizingthe movement of the injection subject with the injection burstparameters to achieve a predetermined injection effect on the injectionsubject.
 11. A method for injecting a subject as defined in claim 1,further comprising: filtering each of said injectate sources.
 12. Amethod for injecting a subject comprising: providing a plurality ofliquid injectate sources; selectively mixing the liquid injectate fromat least one of said liquid injectate sources to achieve a desiredinjectate composition; drawing the desired injectate composition into atleast one pump; supplying said injectate composition at a high pressureto an injection head and filtering the injectate composition as itenters the injection head; delivering at least one constant, highpressure burst of said injectate composition to the subject in a sealedinjection environment; providing relative movement of the subject withrespect to the injection head; and synchronizing the movement of thesubject with the timing, duration, spacing and pressure of the injectionbursts to achieve a predetermined injection effect on the subject.
 13. Amethod for injecting a subject as defined in claim 12, wherein saidproviding step includes: cooling each of the injectate sources to apredetermined temperature with a refrigeration system.
 14. A method forinjecting a subject as defined in claim 12, wherein said mixing stepincludes adding a predetermined and controlled volume of one or more ofsaid injectate sources to a mixing manifold until the desired injectatecomposition is achieved.
 15. A method for injecting a subject as definedin claim 12, further comprising: providing relative movement between theinjection subject and said injection head in between injection bursts toachieve the required injection position for a given injection burst. 16.A method for injecting a subject as defined in claim 12, furthercomprising: providing relative movement between the injection subjectand said injection head during an injection burst to achieve therequired injection effect for a given injection run.
 17. A method forinjecting a subject as defined in claim 12, further comprising:filtering each of said injectate sources.
 18. A method for injecting asubject as defined in claim 12, further comprising: cleaning theinjection head and the sealed injection chamber.
 19. A method forinjecting a subject comprising: providing a totally enclosed injectionsystem and connecting the required process inputs to the totallyenclosed injection system; supplying a plurality of liquid injectatesources within the injection system; mixing said liquid injectatesources in a mixing manifold to achieve a desired injectate composition;drawing the desired injectate composition into at least one pump;supplying said injectate composition at a high pressure to an injectionhead and filtering the injectate composition as it enters the injectionhead; delivering at least one constant, high pressure burst of saidinjectate composition to the subject in a sealed injection chamber;providing a controller for storing process variables for a giveninjection subject; and controlling process variables to achieve apredetermined injection result.
 20. A method for injecting a subject asdefined in claim 19, wherein said controlling step comprises at leastone of: adding a predetermined and controlled volume of at least oneinjectate source to a mixing manifold until the desired injectatecomposition is achieved; monitoring the temperature of at least one ofthe injectate sources with a temperature sensor linked to a remotelylocated control panel; indicating on a touch screen that the injectatetemperature is above a required operational temperature; delayingdelivery of injection bursts to the subject until the output fluidtemperature is equal to or below the required operational temperature;cooling each of the injectate sources to a predetermined temperaturewith a refrigeration system; monitoring the output injectate compositionpressure of the pump with a pressure sensor linked to a remotely locatedcontrol panel; and adjusting the pressure of the injectate compositionentering the injection head to achieve a required injection burstpressure; periodically releasing trapped air from the injection head;moving the injection subject with respect to said injection head;synchronizing the movement of the injection subject with the timing,duration, spacing and pressure of the injection bursts to achieve apredetermined injection effect on the subject; and saving the processvariables for a given injection run.
 21. A method for injecting asubject as defined in claim 19, wherein said controlling step furthercomprises: adjusting air pressure delivered to the pump to ensure thepressure of the fluid at the outlet of the pump provides the requiredinjection effect on the subject.
 22. A method for injecting a subject asdefined in claim 19, further comprising: rinsing the injection system;and cleaning the injection system.
 23. A method for injecting a subjectas defined in claim 22, wherein said controlling step comprises at leastone of: displaying a rinsing control on the touch screen and initiatinga rinsing operation when the control is activated by an operator; anddisplaying a cleaning control on the touch screen and initiating acleaning operation when the control is activated by an operator.
 24. Amethod for flavoring a foodstuff comprising: providing a desired liquidcomposition selected from the group consisting of flavors, colors,tenderizers, marinades, vitamins, minerals, herbal extracts,preservatives, fats, oils, water, anti-microbial solutions,anti-bacterial solutions, medicines, and combinations thereof; providinga needleless injection device having at least one nozzle spaced apartfrom the foodstuff during injection of the foodstuff; and delivering atleast one constant pressure burst of the liquid composition at apressure sufficient to penetrate a surface of the foodstuff.